The rebirth of Lazarus

[mickwinf]

its going to be a long job! thanks for the offer but the 500 is a wet sump so no oil tank needed.

[Oddjob]

Just as an aside but exactly how long was it before Lazarus came back from the dead as he seems overdue 

[mickwinf]

if i was a god it would be sooner! collecting bits as i see them ready for the build, we must arrange pick up of the crankcase, but i need to check the gearbox to see if you have any of the parts i need. will be in touch soon.

[Oddjob]

Mick I have a complete NOS gearbox, every single part is brand new. I intend to fit it in the rebuild of my old engine, I do have quite a few old parts as well from various engines. Depends on what part it is.

The hardest part to find is the middle selector fork, rare as a Stockport virgin over 13

[Johnny4428]

The hardest part to find is the middle selector fork, rare as a Stockport virgin over 13

😂😂😂

[Bryanj]

You need to keep an eye on ebay US and buy a 350 twin selector drum with forks to get the middle fork, but dont tell everybody

[mickwinf]

the selector forks look ok but a couple of the gears were chipped, can single gears be replaced or would it be better to replace the whole cluster?

[K2-K6]

The gears were never made in pairs so shouldn't really matter in reality.

Chipping of teeth though is usually associated with the possibility of a bent fork, so check carefully (two gears trying to run in competition and nipping bits off) or thrust washers, circlips etc being compromised and so letting the gears float, giving a similar outcome of clashing.

Worthwhile checking all the thrusts, location (so the whole shaft can't shift sideways when the forks are used to change gear) to make sure the rebuild doesn't suffer the same.

[mickwinf]

it was the dogs that had broken off

[Oddjob]

Let me know which ones Mick, I'll have a look. I do have a spare 3rd gear IIRC but not sure if it's counter or main shaft 3rd.

[Bryanj]

There is one gear that must be replaced with its mating gear as Honda changed the tooth profile during the years of production, trouble is i cant remember which one, what happened is when you ordered either gear it went to a supercision part number and you got both

[mickwinf]

ok i have had a look at my gearbox and the two broken gears are on the countershaft, the two that slide along moved by the two outer forks. on the parts book pic they are numbered 10 and 12. Also i need the gearchange shaft that the gear lever fits onto as i knackered it getting it out

[Oddjob]

Should have a gearchange shaft Mick.

Countershaft 4th and 5th. I'll have a look at the NOS ones to see how they look and then see about seeing what else I have.

[Oddjob]

Ok Mick, just did a deep dive through my old gearboxes, I threw a few out a couple of years ago as I got sick of looking at them. But it seems I still have at least 2 full boxes lying around.

First off, found a gearchange shaft, will clean it up and inspect it but looks ok at first glance, I know I still have another in another box as I keep moving it to get to smaller pieces. So I'll have at least one good one, hopefully.

No 12 on the diagram is Countershaft top gear, 23491-286-030, I have 1 of those, it's still on the shaft so I'll need to remove the 2 gears in front of it to remove it but looks ok. Will clean and check. Almost certainly another in my other gearbox box but will check this one out first. I also have a spare NOS one for some reason.

No 10 on the diagram is Countershaft Fourth, 23471-286-010.  This is the one I believe that Bryan was referring to as I had to buy both itself and the matching gear Countershaft Low, 23420-323-010. This may be because this gear was superceded from 23420-323-000 which was only fitted to the K0 version of the 500. So it could have had a possible problem when the K0 came out which was rectified in the K1 onward. As both of my spare boxes are from K1's it shouldn't be a problem. I have 2 of 23471-286-010 and 2 of 23420-323-000. One has the removable bush missing but yours should still have it. Need to clean and inspect all of the 4 gears before saying they are ok to use.

I'll let you know the result after the cleaning and inspecting process. Most important that gears are ok as any breakages etc are a bugger to fix after the engines installed.

[mickwinf]

perfect, thanks Ken, let me know when you have checked.